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The U.S. Postal Service dictates that all folded mail pieces without a carrier must be sealed at the open edge in order to make it through the mail stream. Two of the most popular sealing options for products such as brochures, stitched booklets and catalogs are wafer seals and glue spots. Here are a few suggestions to keep in mind when planning your next folded self-mailer project:
Wafer Seals
Wafer seals are affixed to the outer panels of a mail piece and wrap around the open edge to seal it shut. According to postal service regulations, the number of seals required depends on the location of the final fold and orientation of the address on the piece. For example, if the open edge is located at the head of the piece in relationship to the address, only one seal will be needed. If the open edge is located at the foot of the piece below the address, two seals will be needed, located one inch from each corner.
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The amount of wafer seals needed on the piece is determined by the orientation of the address in relationship to the open edge. If the open edge is located at the head, above the address, only one wafer seal is needed. If the open edge is located at the foot, below the address, two wafer seals will be needed to make postal regulations. |
The seals themselves vary in material and appearance. Paper seals are available in translucent, white or colored varieties, and can be printed to include an image or short message. Clear Mylar seals are also available to allow printing underneath to be viewed. While wafer seals may be perforated to facilitate easy opening, it's common for end users to tear paper when attempting to open sealed pieces.
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Wafer seals can double as design element for some applications. This cross-folded inviation is enclosed with a stamped wafer seal. |
Planning Tip: Don't Obscure it - Once placed, paper wafer seals will obscure any printing underneath. When planning your direct mail pieces, be sure to keep images or important copy away from the sealed edge of your piece to ensure they won't be obscured. If this is not possible, clear Mylar seals may be an alternative.
Spot Glue
Spot gluing is a great closure solution for mail pieces with multiple folds, such as a roll-folded brochure. It can also be used to seal the edge of a piece that includes a perfed tear-off. Spot gluing is typically more economical and more efficient than wafer sealing, resulting in lower costs and reduced turnaround times.
EZ-release hot melt adhesives are the most common spot glue formulas used for direct mail applications. EZ-release adhesives are designed to detach with a light pull. Latex-based adhesives are also popular, as they can be applied thinly. However, they aren't recommended for use on thicker stocks, as their longer "open" or cure times can allow in folded panels to pop open before the glue has dried.
Planning Tip: Test for Proper Adhesion
As with any gluing application, spot glues should be tested for proper adhesion on a printed sample prior to production. This is particularly important for mail pieces where image is of utmost importance, as some glue/ink or glue/coating combinations may result in staining once the glue has been rubbed away.
The Rickard Advantage
At Rickard Bindery, our several decades of gluing experience help ensure that your direct mail projects are produced efficiently and attractively. In addition to EZ-release spot gluing and wafer sealing capabilities, our folding, gluing, stitching and attaching services give you a complete range of direct mail production choices. Give us a call today to discuss your next project.
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